I have a downsized 500 cc version which was built for Austria and Italy for tax/insurance reasons (2RX is the model code), so this has some stuff from the later 3AJ model:
- better outout shaft (more teeth for sprocket connection)
- better oil pump of the 3AJ
- modified air intake under seat
This is my travel bike (Saharas etc) since 1987, so most mods are for more ruggedness and more simplicity

- replaced right plastic cover for a mesh wire one to get cooling air to the oil tank
- made ventilation openings into the front fender (before cylinder head)
- electrical oil temp sensor (VDO, drain plug)
- changed the carb for the earlier model one without secondary carb membrane
- got rid of the choke lever in the cockpit for a choke knob sitting directly on the carb
- removed electrical starter for weight loss, put smaller battery in
- removed petrol pump (not needed really)
- better horn
- manual decompressor lever instead of the automatic system
- removed roller type chain guards (top and bottom) and put KTM sliders in
- replaced rear monoshock for a Bilstein, then original shock + extension, then finally settled for a White Power unit
- made a longer side stand due to the longer monoshock, and put an end plate on it for not sagging on soft grounds
- self made carriage system (mild steel, zinc plated)
- self made Aluminium boxes
- self made tank side bags
- heated grips (Daytona)
- extra power socket(s). In the 90ies one small one was enough for a camping light. Later I had to charge camera batteries, then navigation system - currently there are three sockets in use.
- RAM mount balls for cam and navigation
- stainless steel exhaust pipes (original ones did not last)
- SITO exhaust damper (original one did not last)
- Aluminium reinforcement for the front fender
- headlight protector (mesh wire)
- small wind shield
- standard indicator relais (car type, three wire)
- modified sprocket nut (welded a 22 mm nut on the huge original nut to change sprockets without needing that big socket)
- replaced horn button (broke) for a self made one (I have a lathe)
- modified seat mounting, it is now strapped down with a fast-lock luggage strap
- modified seat and side cover for easier access to oil dipstick
- engine repairs: oversize piston due to malfunctioning choke, 5th gear at about 70.000, original engine destruction close to 100.000 km due to lost oil plug
- replacement engine from a 3AJ (Austrian model again, 500 cc) modified with a 1VJ side cover to regain the kick starter.
- Twin-Air filter from the Netherlands
- Acerbis Rallye hand guards (lever protection)
- right petcock with a reserve position (not sure which bike that is from)

My aluminium Tesch panniers weigh about twice as much as the OEM bmw panniers I have on the GS, which is ok for roads and any gentle off road tracks I use. If memory serves me right they are 5 kg each so total of 5 kg extra weight for using aluminium. From threads on advrider I get the impression that soft luggage is best if you are spending a lot of time off road and don't need to worry about theft in big cities and towns.

As for my luggage system:
I use soft panniers on my bicycle (pushbike) touring adventures, so I would even have some waterproof bags available.
To be completely honest, I ruined one bag on my Albania trip which was a pain. Have gone back to the box system.

TESCH boxes are HUGE and made of 2 mm Aluminium.
As I built the boxes myself I tried to make them light and sturdy (1.5 mm), so one box is around 4 kg.
The older German DÄRR boxes from the 80/90s are a bit below that with 3.4 kg /same size (1.2 mm).

The steel rack is about 7 kg (from the top of my head)

So 15 kg in total for me.

If we are talking bags (and a kind of rack/rail for them) how light is your system then?

I would assume it is 5-6 kg in bags and another 3-5 kg for a light rack to fix the bags to? So 10ish kg?

Andy

By the way those boxes and detachable lids serve some extra purposes when travelling. Stool, table, mounting stand, oil pan, work bench etc while a soft bag is quite monofunctional aside from sitting on it or using it as a pillow.

Last edited by motorang on Tue Dec 18, 2018 4:18 pm, edited 1 time in total.

Hi Motorang. The Tesch bags are heavy and strong. I know Bernd and he has visited me so I feel good using bags where I know who made them. The rack weighs 3.7kg, small bag is 4.9kg and the large one is 5.7kg, total weight is 14.3kg. This is for my R100GS and it feels solid when riding. I like his hinge design but always worry a little about his lock as if you don't lock it properly you could lose a lid- I might fit a backup clasp as a failsafe measure.